MEEN 30133 MACHINE ELEMENTS 1

LESSON 1 INTRODUCTION

Unit 1: Design of Machine Elements

Overview

This chapter covers those topics of greatest importance to a mechanical engineer whose
design activity is so often devoted to machines and systems of machine.

Learning Objectives:

After successful completion of this module, the students should be able to:
1. Understand the meaning of certain fundamental concepts and principles used in
Machine Elements.
2. Compare between design synthesis and design analysis.

Course Materials:

Machine Design
Machine design is defined as the use of scientific principles, technical information and
imagination in the description of a machine or a mechanical system to perform specific functions
with maximum economy and efficiency. This definition of machine design contains the following
important features:
▪ A designer uses principles of basic and engineering sciences such as physics,
mathematics, statics and dynamics, thermodynamics and heat transfer, vibrations and
fluid mechanics.
▪ The designer has technical information of the basic elements of a machine. These
elements include fastening devices, chain, belt and gear drives, bearings, oil seals and
gaskets, springs, shafts, keys, couplings, and so on. A machine is a combination of
these basic elements. The designer knows the relative advantages and disadvantages
of these basic elements and their suitability in different applications.
▪ The designer uses his skill and imagination to produce a configuration, which is a
combination of these basic elements. However, this combination is unique and different
in different situations. The intellectual part of constructing a proper configuration is
creative in nature.
▪ The final outcome of the design process consists of the description of the machine. The
description is in the form of drawings of assembly and individual components.
▪ A design is created to satisfy a recognized need of customer. The need may be to
perform a specific function with maximum economy and efficiency.

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SUBJECT: MEEN 30133 – MACHINE ELEMENTS 1
COMPILED BY: JHAY AHR C. FLORES, ME
Basic Procedure of Machine Design
The basic procedure of machine design consists of a step-by-step approach from given
specifications about the functional requirements of a product to the complete description in the
form of drawings of the final product.
▪ Product Specifications
▪ Selection of Mechanism
▪ Layout of Configuration
▪ Preparation of Drawings

Basic Requirements of Machine Elements

A machine consists of machine elements. Each part of a machine, which has motion
with respect to some other part, is called a machine element.

The broad objective of designing a machine element is to ensure that it preserves its
operating capacity during the stipulated service life with minimum manufacturing and operating
costs. In order to achieve this objective, the machine element should satisfy the following basic
requirements:
▪ Strength - A machine part should not fail under the effect of the forces that act on it. It
should have sufficient strength to avoid failure either due to fracture or due to general
yielding.
▪ Rigidity - A machine component should be rigid, that is, it should not deflect or bend too
much due to forces or moments that act on it.
▪ Wear Resistance - Wear is the main reason for putting the machine part out of order. It
reduces useful life of the component. Wear also leads to the loss of accuracy of machine
tools.
▪ Minimum Dimensions and Weight - A machine part should be sufficiently strong, rigid
and wear resistant and at the same time, with minimum possible dimensions and weight.
▪ Manufacturability - Manufacturability is the ease of fabrication and assembly. The
shape and material of the machine part should be selected in such a way that it can be
produced with minimum labour cost.
▪ Safety - The shape and dimensions of the machine parts should ensure safety to the
operator of the machine.
▪ Conformance to Standards - A machine part should conform to the national or
international standard covering its profile, dimensions, grade and material.
▪ Reliability - Reliability is the probability that a machine part will perform its intended
functions under desired operating conditions over a specified period of time.
▪ Maintainability - A machine part should be maintainable. Maintainability is the ease with
which a machine part can be serviced or repaired.
▪ Minimum: Life-cycle Cost - Life-cycle cost of the machine part is the total cost to be
paid by the purchaser for purchasing the part and operating and maintaining it over its
life span.

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SUBJECT: MEEN 30133 – MACHINE ELEMENTS 1
COMPILED BY: JHAY AHR C. FLORES, ME
Design of Machine Elements
Design of machine elements is the most important step in the complete procedure of
machine design. In order to ensure the basic requirements of machine elements, calculations
are carried out to find out the dimensions of the machine elements.

Basic Procedure of Design of Machine Element

▪ Specification of Function
▪ Determination of Forces
▪ Selection of Material
▪ Failure Criterion
▪ Determination of Dimensions
▪ Design Modifications
▪ Working Drawing

Design Synthesis
Design synthesis is defined as the process of creating or selecting configurations,
materials, shapes and dimensions for a product. There is a basic difference between design
analysis and design synthesis. In design analysis, the designer assumes a particular
mechanism, a particular material and mode of failure for the component. With the help of this
information, he determines the dimensions of the product. However, design synthesis does not
permit such assumptions. Here, the designer selects the optimum configuration from a number
of alternative solutions.

Use of Standards in Design

Standardization is defined as obligatory norms, to which various characteristics of a product
should conform. The characteristics include materials, dimensions and shape of the component,
method of testing and method of marking, packing and storing of the product. The following
standards are used in mechanical engineering design:
▪ Standards for Materials, their Chemical Compositions, Mechanical Properties and Heat
Treatment
▪ Standards for Shapes and Dimensions of Commonly used Machine Elements
▪ Standards for Fits, Tolerances and Surface Finish of Component
▪ Standards for Testing of Products
▪ Standards for Engineering Drawing of Components

Ergonomic Considerations in Design

Ergonomics is defined as the relationship between man and machine and the application
of anatomical, physiological and psychological principles to solve the problems arising from
man–machine relationship.
From design considerations, the topics of ergonomic studies are as follows:
▪ Anatomical factors in the design of a driver’s seat
▪ Layout of instrument dials and display panels for accurate perception by the operators
▪ Design of hand levers and hand wheels
▪ Energy expenditure in hand and foot operations
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SUBJECT: MEEN 30133 – MACHINE ELEMENTS 1
COMPILED BY: JHAY AHR C. FLORES, ME
 ▪ Lighting, noise and climatic conditions in machine environment

Activities:

Assignment Answer the following:

1. What is the final outcome of a machine design process?
2. What is standardization?
3. What are the three basic types of standards used in a design office?
4. What do you understand by size of a product? Give examples.
5. Explain man–machine joint system.

Assessment:

Answer the following:

1. What are the basic requirements of a machine element?
2. What are the steps involved in design of a machine element?
3. Define design synthesis.
4. Distinguish between design synthesis and design analysis.
5. What is industrial design?

References:

▪ V.M. Faires (1969). Design of Machine Elements. 4 th ed. EDCA Publishing and
Distributing Corporation

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SUBJECT: MEEN 30133 – MACHINE ELEMENTS 1
COMPILED BY: JHAY AHR C. FLORES, ME
LESSON 2 ENGINEERING MATERIALS

Unit 1: Properties

Overview

This chapter covers the different number of available materials and the quantity of
information on their properties that will serve as a guide for machine design.

Learning Objectives:

After successful completion of this module, the students should be able to:
1. Classify the mechanical properties of the material.
2. Identity the different alloying elements.

Course Materials:

Stress–Strain Diagrams
A very useful information concerning the behaviour of material and its usefulness for
engineering applications can be obtained by making a tension test and plotting a curve showing
the variation of stress with respect to strain. A tension test is one of the simplest and basic tests
and determines values of number of parameters concerned with mechanical properties of
materials like strength, ductility and toughness. The following information can be obtained from
a tension test:
▪ Proportional limit
▪ Elastic limit
▪ Modulus of elasticity
▪ Yield strength
▪ Ultimate tension strength
▪ Modulus of resilience
▪ Modulus of toughness
▪ Percentage elongation
▪ Percentage reduction in area

Mechanical Properties of Engineering Materials

Materials are characterized by their properties. They may be hard, ductile or heavy. Conversely,
they may be soft, brittle or light. The mechanical properties of materials are the properties that
describe the behaviour of the material under the action of external forces.

The following mechanical properties:

1. strength - the ability of the material to resist, without rupture, external forces causing
various types of stresses.

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SUBJECT: MEEN 30133 – MACHINE ELEMENTS 1
COMPILED BY: JHAY AHR C. FLORES, ME
 2. elasticity - the ability of the material to regain its original shape and size after the
deformation, when the external forces are removed.
3. plasticity - the ability of the material to retain the deformation produced under the load
on a permanent basis.
4. stiffness - the ability of the material to resist deformation under the action of an external
load.
5. resilience - the ability of the material to absorb energy when deformed elastically and to
release this energy when unloaded.
6. toughness - ability of the material to absorb energy before fracture takes place.
7. malleability - ability of a material to deform to a greater extent before the sign of crack,
when it is subjected to compressive force.
8. ductility - ability of a material to deform to a greater extent before the sign of crack,
when it is subjected to tensile force.
9. brittleness - property of a material which shows negligible plastic deformation before
fracture takes place
10. hardness - the resistance of the material to penetration or permanent deformation.

Cast Iron
Cast iron is a generic term, which refers to a family of materials that differ widely in their
mechanical properties. By definition, cast iron is an alloy of iron and carbon, containing more
than 2% of carbon. In addition to carbon, cast iron contains other elements like silicon,
manganese, sulphur and phosphorus. There is a basic difference between steels and cast iron.
Steels usually contain less than 1% carbon while cast iron normally contains 2 to 4% carbon.

Typical composition of ordinary cast iron is as follows:

▪ carbon = 3.0 – 4.0%
▪ silicon = 1.0 – 3.0%
▪ manganese = 0.5 – 1.0%
▪ sulphur = up to 0.1%
▪ phosphorus = up to 0.1%
▪ iron = remainder

BIS System of Designation of Steels

A large number of varieties of steel are used for machine components. Steels are
designated by a group of letters or numbers indicating any one of the following three properties:
▪ tensile strength;
▪ carbon content; and
▪ composition of alloying elements.

Plain-Carbon Steels
Depending upon the percentage of carbon, plain carbon steels are classified into the following
three groups:
▪ Low Carbon Steel contains less than 0.3% carbon. It is popular as ‘mild steel’. Low
carbon steels are soft and very ductile.
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SUBJECT: MEEN 30133 – MACHINE ELEMENTS 1
COMPILED BY: JHAY AHR C. FLORES, ME
 ▪ Medium Carbon Steel has a carbon content in the range of 0.3% to 0.5%. It is popular
as machinery steel. Medium carbon steel is easily hardened by heat treatment
▪ High Carbon Steel contains more than 0.5% carbon. They are called hard steels or tool
steels. High carbon steels respond readily to heat treatments

Free-Cutting Steels
Steels of this group include carbon steel and carbon–manganese steel with a small
percentage of sulphur. Due to addition of sulphur, the machinability of these steels is improved.

Alloy Steels
Alloy steel is defined as carbon steel to which one or more alloying elements are added
to obtain certain beneficial effects.

Alloying elements can affect constitution, characteristics and behaviour of these steels. The
effects of major alloying elements are as follows:
1. Silicon is present in almost all steels. It increases strength and hardness without
lowering the ductility. Silicon is purposely added in spring steel to increase its toughness.
2. Manganese Most steels contain some manganese remaining from the deoxidisation and
desulphurisation processes.
3. Nickel increases strength, hardness and toughness without sacrificing ductility. It
increases hardenability of steel and impact resistance at low temperature. The main
effect of nickel is to increase toughness by limiting grain growth during the heat
treatment process.
4. Chromium increases hardness and wear resistance. Chromium steel components can
be readily hardened in heavy sections.
5. Molybdenum increases hardness and wear resistance. It resists softening of steel
during tempering and heating.
6. Tungsten Tungsten and molybdenum have similar effects. It is an expensive alloying
element and about 2 to 3 per cent tungsten is required to replace 1 per cent of
molybdenum. It is an important alloying element in tool steels.

Overseas Standards
Cast iron and steel are the essential ingredients in any product. A large variety of steel and cast
iron is developed for a number of applications. In our country, collaborations with foreign
industries have resulted in use of different overseas standards and designations.

▪ The American Society for Testing Materials (ASTM) has classified grey cast iron by
means of a number.
▪ In Germany, Deutches Institut Fuer Normung (DIN) has specified grey cast iron by
minimum ultimate tensile strength in kgf/mm2.
▪ A numbering system for carbon and alloy steels is prescribed by the Society of
Automotive Engineers (SAE) of USA and American Iron and Steel Institute (AISI).

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SUBJECT: MEEN 30133 – MACHINE ELEMENTS 1
COMPILED BY: JHAY AHR C. FLORES, ME